EP2197794B1 - Crystallised material with hierarchised porosity and containing silicon - Google Patents

Abstract

Hierarchical porous material comprises at least two spherical elementary particles having a maximum diameter of 200 microns, where at least one of the spherical particles comprise a silicon oxide based matrix and having crystallized walls, the material has a macroporous volume measured by mercury porosimetry of 0.05-1 ml/g, a mesoporous volume measured by nitrogen volumetry of 0.01-1 ml/g and a microporous volume measured by nitrogen volumetry of 0.03-0.4 ml/g. An independent claim is included for a preparation of the material, comprising preparing a clear solution containing precursor elements of zeolite, such as structuring agent, at least a silica precursor and optionally at least a precursor of an element X comprising aluminum, iron, boron, indium and gallium, mixing at least one surfactant and the clear solution into a solution, spraying the solution by aerosol obtained in the mixing step for the formation of spherical droplets, drying the droplets, and eliminating the structuring agent and the surfactant to obtain an amorphous material with hierarchical porosity in the range of microporosity, mesoporosity and macroporosity.

Description

The present invention relates to the field of materials comprising silicon, in particular metallosilicate materials and more specifically aluminosilicate materials, having a hierarchical porosity in the field of microporosity, mesoporosity and macroporosity. It also relates to the preparation of these materials which are obtained by the use of the so-called "aerosol" synthesis technique.

State of the art

New synthesis strategies to obtain well-defined porosity materials in a very wide range, ranging from microporous materials to macroporous materials through materials with hierarchical porosity, that is to say having pores of several sizes. have been very widely developed in the scientific community since the mid-1990s ( GJ AA Soler-Illia, C. Sanchez, B. Lebeau, J. Patarin, Chem. Rev., 2002, 102, 4093 ). In particular, many studies relate to the development of materials having a zeolite microporosity and a mesoporosity so as to simultaneously benefit from the zeolite specific catalytic properties and catalytic and especially textural properties of the mesoporous phase.

A technique frequently used to generate materials having this bi-porosity is to create directly within zeolite crystals mesopores by subjecting the latter a hydrothermal treatment under water vapor also called "steaming". Under the effect of this treatment, the mobility of the tetrahedral atoms that make up the framework of the zeolite is increased to the point that some of these atoms are extracted from the network, which causes the formation of amorphous zone, which can be released to leave the room for mesoporous cavities ( AH Jansen, AJ Koster, KP De Jong, J. Phys. Chem. B, 2002, 106, 11905 ). The formation of such cavities can also be obtained by acid treatment of the zeolite ( H. Ajot, JF Joly, J. Lynch, F. Raatz, P. Caullet, Stud. Surf. Sci. Catal., 1991, 62, 583 ). However, these methods have the disadvantage of rendering part of the zeolite partially amorphous and of modifying its properties by variation of the chemical composition. In all cases, the mesoporosity introduced in this way makes it possible to eliminate or at least limit the problems of diffusional limitations encountered in microporous materials, the mesopores having well-diffusing factors. larger than the micropores and thus allowing access to the active sites of the zeolite ( PB Weisz, Chemtech, 1973, 3, 498 ).

More recently, many studies have focused on the development of mixed mesostructured / zeolite materials, the mesostructured materials having the additional advantage of having a perfectly organized and calibrated porosity in the range of mesopores.

We recall here briefly that the mesostructured materials are conventionally obtained via so-called soft chemistry synthesis methods which consist of bringing into contact in aqueous solution or in polar solvents inorganic precursors with structuring agents, generally molecular or macromolecular, ionic surfactants. or neutral. The control of electrostatic or hydrogen bonding interactions between the inorganic precursors and the structuring agent together with hydrolysis / condensation reactions of the inorganic precursor leads to a cooperative assembly of the organic and inorganic phases generating micellar aggregates of uniformly sized surfactants. and controlled within an inorganic matrix. The release of the porosity is then obtained by removing the surfactant, which is conventionally carried out by chemical extraction processes or by heat treatment. Depending on the nature of the inorganic precursors and the structuring agent used as well as the operating conditions imposed, several families of mesostructured materials have been developed, such as the M41S family obtained via the use of quaternary ammonium salts as a structuring agent ( JS Beck, JC Vartuli, WJ Roth, ME Leonowicz, Kresge CT, KD Schmitt, CT-W. Chu, DH Olson, EW Sheppard, SB McCullen, JB Higgins, J. Schlenker, J. Am. Chem. Soc., 1992, 114, 27, 10834 ) or the family of SBA obtained via the use of triblock copolymers as structuring agents ( D. Zhao, J. Feng, Q. Huo, N. Melosh, GH Fredickson, BF Chmelka, GD Stucky, Science, 1998, 279, 548 ).

Several synthetic techniques for the preparation of these mixed mesostructured / zeolite materials have thus been listed in the open literature. A first synthesis technique consists of synthesizing in the first step a mesostructured aluminosilicate material according to the conventional methods explained above and then, in the second step, impregnating this material with a structuring agent usually used in the synthesis of zeolite materials. A suitable hydrothermal treatment leads to a zeolitization of the amorphous walls (or walls) of the mesostructured aluminosilicate ( KR Koletstra, H. van Bekkum, JC Jansen, Chem. Commun., 1997, 2281 ; DT On, S. Kaliaguine, Angew. Chem. Int. Ed., 2001, 40, 3248 ; DT On, D. Lutic, S. Kaliaguine, Micropor. Mesopor. Mater., 2001, 44, 435 ; MJ Verhoef, PJ Kooyman, JC van der Waal, MS Rigutto, JA Peters, H van Bekkum, Chem. Mater., 2001, 13, 683 ). A second synthesis technique is this time to bring together a colloidal solution of zeolite seeds with a surfactant usually used to create a mesostructuration of the final material. The idea used here is to simultaneously generate the development of an inorganic matrix with organized mesoporosity and the growth within this matrix of zeolite seeds so as to ideally obtain a mesostructured aluminosilicate material having walls (or walls). crystallized ZT Zhang, Y. Han, Xiao FS, Oiu SL, Zhu L, Wang RW, Yu Y., Z. Zhang, Wu Zou, YQ Wang, Sun HP, Zhao DY, Y. Wei, J. Am. Chem. Soc., 2001, 123, 5014 . An alternative to these two techniques consists of a mixture of aluminum precursors and silicon in the presence of two structuring agents, one capable of generating a zeolite system, the other likely to generate mesostructuration. This solution is then subjected to two crystallization steps using variable hydrothermal treatment conditions, a first step which leads to the formation of the mesoporous structure with organized porosity and a second step which leads to the zeolitization of the walls (or walls ) amorphous ( A. Karlsson, M. Stöcker, R. Schmidt, Micropor. Mesopor. Mater., 1999, 27, 181 ; A. Karlsson, M. Stöcker, R. Schmidt, Stud. Surf. Sci. Catal., 2000, 129, 99 . All of these synthesis methods have the disadvantage of damaging the mesostructure and thus losing the advantages thereof in the case where the growth of zeolite seeds or the zeolitization of the walls is not perfectly controlled, this which makes these techniques tricky to implement.

We note that it is also possible to directly develop mesostructured / zeolite composite materials in order to benefit from the catalytic properties specific to each of these phases. This can be done by heat treatment of a mixture of a zeolite seed solution and a solution of mesostructured aluminosilicate seeds ( P. Prokesova, S. Mintova, J. Cejka, T. Bein, Micropor. Mesopor. Mater., 2003, 64, 165 ) or by growth of a zeolite layer on the surface of a pre-synthesized mesostructured aluminosilicate ( DT On, S. Kaliaguine, Angew. Chem. Int. Ed., 2002, 41, 1036 ).

Excluding the zeolite zeolite materials obtained by post-treatment of a zeolite, we note that, from an experimental point of view, all these materials are obtained by direct precipitation of inorganic precursors in the presence or absence of structuring agents within an aqueous solution or in polar solvents, this step being mostly followed by one or more autoclave ripening steps. The elementary particles usually obtained do not have a regular shape and are generally characterized by a size ranging from 200 to 500 nm.

Several studies have also focused on the development of materials with both micro and macroporosity. By way of example, one of the most common synthetic methods consists of using polystyrene beads as a macroporosity generating element and creating around these beads a zeolite network ( GS Zhu, Qiu SL, Gao FF, Li DS, YF Li, Wang RW, Gao B., Li BS, YH Guo, Xu RR, Z. Liu, O. Terasaki, J. Mater. Chem., 2001, 11, 6, 1687 ).

The document EP1627853 discloses a hierarchical porosity material consisting of at least two elementary spherical particles, each of said spherical particles comprising zeolitic nanocrystals having a pore size of between 0.2 and 2 nm and a mesostructured silicon oxide matrix, having a pore size between 1.5 and 30 nm and having amorphous walls of thickness between 1 and 20 nm, said elementary spherical particles having a maximum diameter of 10 microns.

Summary of the invention

The invention relates to a material with a hierarchical porosity consisting of at least two elementary spherical particles having a maximum diameter of 200 microns, at least one of said spherical particles comprising at least one matrix based on silicon oxide, said material exhibiting a macroporous volume measured by mercury porosimetry of between 0.05 and 1 ml / g, a mesoporous volume measured by nitrogen volumetry of between 0.01 and 1 ml / g and a microporous volume measured by nitrogen volumetry. between 0.03 and 0.4 ml / g, said matrix having crystallized walls, which consist of zeolite entities at the origin of the microporosity of the material. Said matrix based on silicon oxide optionally further comprises at least one element X selected from aluminum, iron, boron, indium and gallium, preferably aluminum. The present invention also relates to the preparation of the material according to the invention. The method for preparing the material according to the invention comprises a) the preparation of a clear solution containing the precursor elements of zeolitic entities, namely at least one structuring agent, at least one silicic precursor and optionally at least one precursor of at least one element X selected from aluminum, iron, boron, indium and gallium; b) mixing in solution at least one surfactant and at least said clear solution obtained according to a); c) the aerosol atomization of said solution obtained at

step b) to lead to the formation of spherical droplets; d) drying said droplets; e) autoclaving the particles obtained according to d); f) drying said particles obtained according to e) and g) the removal of said structuring agent and said surfactant to obtain a crystallized material with hierarchical porosity in the range of microporosity, mesoporosity and macroporosity.

The microporosity induced by the crystallized walls of zeolite nature of the material according to the invention is consecutive not only to the use of a solution containing the precursor elements of zeolitic entities according to step a) of the process according to the invention, but also to the implementation of an autoclaving of the particles in accordance with step e) of the process for preparing the material according to the invention. The mesoporosity and the macroporosity of the material according to the invention are consecutive to the phenomenon of phase separation by spinodal decomposition of the organic phase generated by the presence of the surfactant and the inorganic phase resulting from the solution containing the precursor elements of zeolitic entities, this phase separation phenomenon being induced by the so-called aerosol technique according to step c) of the process according to the invention.

Interest of the invention

The material according to the invention, which comprises a mesoporous and macroporous inorganic matrix, based on silicon oxide, with microporous and crystallized walls, simultaneously exhibits the structural, textural and acid-base properties of the materials of the zeolite family and the textural properties of mesoporous materials and macroporous materials. The presence within the same spherical particle of micrometric or even nanometric size of mesopores and macropores in a microporous and crystallized inorganic matrix leads to a privileged access of the reagents and products of the reaction to the microporous sites during the use of the material. according to the invention as an adsorbent or as an acidic solid in potential industrial applications. In addition, the material according to the invention consists of spherical elementary particles, the diameter of these particles being at most equal to 200 μm, preferably less than 100 μm, advantageously varying from 50 nm to 20 μm, very advantageously to 50 nm. at 10 μm and even more advantageously from 50 to 300 nm. The limited size of these particles as well as their homogeneous spherical shape makes it possible to have a better diffusion of the reagents and the products of the reaction when the material according to the invention is used in potential industrial applications compared with materials. known from the state of the art in the form of elementary particles of non-homogeneous shape, that is to say irregular, and size often greater than 500 nm.

Presentation of the invention

The subject of the present invention is a material with a hierarchical porosity consisting of at least two elementary spherical particles having a maximum diameter of 200 microns, at least one of said spherical particles comprising at least one matrix based on silicon oxide and having crystallized walls, said material having a macroporous volume measured by mercury porosimetry of between 0.05 and 1 ml / g, a mesoporous volume measured by nitrogen volumetry of between 0.01 and 1 ml / g and a microporous volume measured by nitrogen volumetry between 0.03 and 0.4 ml / g.

For the purposes of the present invention, the term "hierarchically porous material" means a material having at least one, and generally several, spherical particles (s) having a triple porosity: a macroporosity characterized by a macroporous mercury volume included in a range ranging from 0.05 to 1 ml / g and preferably in a range of from 0.1 to 0.3 ml / g, a mesoporosity characterized by a mesoporous volume measured by nitrogen volumetry in a range of from 0 to , 01 to 1 ml / g and preferably in a range varying from 0.1 to 0.6 ml / g and a zeolite type microporosity whose characteristics (zeolite structural type, chemical composition of the zeolite framework) are function zeolite entities constituting the crystallized walls of each of the matrices spherical particles of the material according to the invention. The macroporosity is also characterized by the presence of macroporous domains ranging from 50 to 1000 nm and preferably in a range varying from 80 to 500 nm and / or resulting from an intraparticular textural macroporosity, the mesoporosity is also characterized by the presence of mesoporous domains in a range of 2 to 50 nm and preferably in a range of 10 to 50 nm. The material according to the invention may also advantageously have elementary spherical particles without mesoporosity. It should be noted that a porosity of microporous nature may also result from the interlaying of the surfactant, used during the preparation of the material according to the invention, with the inorganic wall at the level of the organic-inorganic interface developed during the treatment. production of said material according to the invention. According to the invention, the matrix based on silicon oxide each forming spherical particles of the material according to the invention has crystallized walls consisting of zeolite entities, which are at the origin of the microporosity present within each spherical particles of the material according to the invention. Any zeolite and in particular, but not exhaustively, those listed in "Atlas of zeolite framework types", 5th revised edition, 2001, C. Baerlocher, WM Meier, DH Olson can be used for the formation of the zeolite entities constituting the crystallized walls of the matrix of each of the particles of the material according to the invention as soon as the dissolution of the precursor elements of these entities, namely at least one structuring agent, at least a silicic precursor and optionally at least one precursor of at least one element X selected from aluminum, iron, boron, indium and gallium, preferably aluminum, lead to obtaining a solution clear. The zeolite entities constituting the crystallized walls of the matrix of each of the particles of the material according to the invention and at the origin of the microporosity thereof preferably comprise at least one zeolite chosen from zeolites ZSM-5, ZSM-48 , ZSM-22, ZSM-23, ZBM-30, EU-2, EU-11, Silicalite, Beta, Zeolite A, Faujasite, Y, USY, VUSY, SDUSY, Mordenite, NU-87, NU-88, NU- 86, NU-85, IM-5, IM-12, Ferrierite and EU-1. In a very preferred manner, the zeolite entities constituting the crystallized walls of the matrix of each of the particles of the material according to the invention comprise at least one zeolite chosen from zeolites of structural type MFI, BEA, FAU and LTA.

According to the invention, the matrix based on silicon oxide forming each of the elementary spherical particles of the material according to the invention is either entirely silicic or it comprises, in addition to silicon, at least one element X chosen from aluminum iron, boron, indium and gallium, preferably aluminum. Thus, the zeolite entities constituting the crystallized walls of the matrix of each of the spherical particles of the material according to the invention and at the origin of the microporosity thereof advantageously comprise at least one zeolite either entirely silicic or containing, besides silicon at least one element X selected from aluminum, iron, boron, indium and gallium, preferably aluminum. When X is aluminum, the matrix of the material is in this case an aluminosilicate. This aluminosilicate has a Si / Al molar ratio equal to that of the solution of the silicic and aluminic precursors leading to the formation of the zeolite entities constituting the crystallized walls of the matrix. According to the invention, said elementary spherical particles constituting the material according to the invention have a maximum diameter equal to 200 microns, preferably less than 100 microns, advantageously between 50 nm and 20 μm, very advantageously between 50 nm and 10 nm. μm, and even more advantageously between 50 and 300 nm. More specifically, they are present in the material according to the invention in the form of aggregates.

The material according to the invention advantageously has a specific surface area of between 100 and 1100 m ² / g and very advantageously between 200 and 800 m ² / g.

The present invention also relates to the preparation of the material according to the invention. Said method for preparing the material according to the invention comprises: a) the preparation of a clear solution containing the precursor elements of zeolitic entities, namely at least one structuring agent, at least one silicic precursor and optionally at least one precursor of at least one element X selected from aluminum, iron, boron, indium and gallium, preferably aluminum; b) mixing in solution at least one surfactant and at least said clear solution obtained according to a); c) aerosol atomizing said solution obtained in step b) to lead to the formation of spherical droplets; d) drying said droplets; e) autoclaving the particles obtained according to d); f) drying said particles obtained according to e) and g) the removal of said structuring agent and said surfactant to obtain a crystallized material with hierarchical porosity in the range of microporosity, mesoporosity and macroporosity.

According to step a) of the preparation process according to the invention, the clear solution containing the precursor elements of zeolitic entities, namely at least one structuring agent, at least one silicic precursor and optionally at least one precursor of at least one less an X element selected from aluminum, iron, boron, indium and gallium, preferably aluminum, is made from operating protocols known to those skilled in the art.

The silicic precursor used for the implementation of step a) of the process according to the invention is chosen from the precursors of silicon oxide well known to those skilled in the art. In particular, it is advantageous to use a silicic precursor chosen from the silica precursors usually used in the synthesis of zeolites, for example uses solid silica powder, silicic acid, colloidal silica, dissolved silica or tetraethoxysilane also called tetraethylorthosilicate (TEOS). Preferably, the silicic precursor is TEOS.

The precursor of the element X, optionally used for the implementation of step a) of the process according to the invention, can be any compound comprising the element X and which can release this element in solution, in particular in aqueous solution or aquo-organic, in reactive form. In the preferred case where X is aluminum, the aluminum precursor is advantageously an inorganic aluminum salt of formula AlZ ₃ , Z being a halogen, a nitrate or a hydroxide. Preferably, Z is chlorine. The aluminum precursor may also be an aluminum sulphate of formula Al ₂ (SO ₄ ) ₃ . The aluminic precursor can also be an organometallic precursor of formula Al (OR) ₃ or R = ethyl, isopropyl, n-butyl, s-butyl (Al (O ^s C ₄ H ₉ ) ₃ ) or t-butyl or a chelated precursor such as aluminum acetylacetonate (Al (C ₅ H ₈ O ₂ ) ₃ ). Preferably, R is s-butyl. The aluminum precursor may also be sodium aluminate or alumina proper in one of its crystalline phases known to those skilled in the art (alpha, delta, teta, gamma), preferably in hydrated form or which can be hydrated.

It is also possible to use mixtures of the precursors mentioned above. Some or all of the aluminic and silicic precursors may optionally be added in the form of a single compound comprising both aluminum atoms and silicon atoms, for example an amorphous alumina silica.

The structuring agent used for carrying out step a) of the process according to the invention may be ionic or neutral depending on the zeolite to be synthesized. It is common to use the structuring agents of the following non-exhaustive list: nitrogenous organic cations such as tetrapropylammonium (TPA), elements of the family of alkalis (Cs, K, Na, etc.), ethercouronnes, diamines and any other structuring agent well known to those skilled in the art for the synthesis of zeolite.

The clear solution containing the zeolite entity precursor elements according to step a) of the process for preparing the material according to the invention is generally obtained by preparing a reaction mixture containing at least one silicic precursor, optionally at least one precursor of at least one precursor. at least one element X selected from aluminum, iron, boron, indium and gallium, preferably at least one aluminum precursor, and at least one structuring agent. The reaction mixture is either aqueous or aquo-organic, by example a water-alcohol mixture. It is preferred to work in a basic reaction medium during the various steps of the process according to the invention in order to promote the development of the zeolite entities constituting the crystallized walls of the matrix of each of the particles of the material according to the invention. The basicity of the solution is advantageously ensured by the basicity of the structuring agent used or by basification of the reaction mixture by the addition of a basic compound, for example an alkali metal hydroxide, preferably sodium hydroxide. . The reaction mixture may be placed under hydrothermal conditions under autogenous pressure, optionally by adding a gas, for example nitrogen, at a temperature between room temperature and 200 ° C., preferably between ambient temperature and 170 ° C. and still more preferably at a temperature which does not exceed 120 ° C. until the formation of a clear solution containing the precursor elements of the zeolite entities constituting the crystallized walls of the matrix of each of the spherical particles of the material according to the invention . According to a preferred procedure, the reaction mixture containing at least one structuring agent, at least one silicic precursor and optionally at least one precursor of at least one element X selected from aluminum, iron, boron, indium and the gallium is cured at ambient temperature so as to obtain a clear solution containing the precursor elements of zeolite seeds capable of generating the formation of crystallized zeolite entities during the step e) of autoclaving the process for preparing the material according to the invention.

According to step a) of the process according to the invention, the precursor elements of the zeolitic entities present in the clear solution are synthesized according to operating protocols known to those skilled in the art. In particular, for a material according to the invention in which the matrix of each particle consists of zeolite beta entities, a clear solution containing precursor elements of zeolite beta entities is produced from the operating protocol described by P. Prokesova, S. Mintova, J. Cejka, T. Bein et al., Micropor. Mesopor. Mater., 2003, 64, 165 . For a material according to the invention in which the matrix of each particle consists of zeolite Y entities, a clear solution containing precursor elements of zeolite Y entities is produced from the operating protocol described by Y. Liu, WZ Zhang, TJ Pinnavaia et al., J. Am. Chem. Soc., 2000, 122, 8791 . For a material according to the invention in which the matrix of each particle consists of faujasite zeolite entities, a clear solution containing precursor elements of zeolite faujasite entities is produced from the operating protocol described by KR Kloetstra, HW Zandbergen, Jansen CJ, H. vanBekkum, Microporous Mater., 1996, 6, 287 . For a material according to the invention in which the matrix of each particle consists of ZSM-5 zeolite entities, a clear solution containing precursor elements of ZSM-5 zeolite species is carried out from the operating protocol described by AE Persson, BJ Schoeman, J. Sterte, J.-E. Otterstedt, Zeolifes, 1995, 15, 611 , the exact operating protocol which is the subject of example 1 of the present application. In the particular case of a purely silicic material, the clear solution containing the precursor elements of zeolite silicalite species constituting the walls of the material according to the invention is advantageously made from the operating protocol described by AE Persson, BJ Schoeman, J. Sterte, J.-E. Otterstedt, Zeolites, 1994, 14, 557 .

According to step b) of the process for preparing the material according to the invention, the surfactant used is an ionic or nonionic surfactant or a mixture of both. Preferably, the ionic surfactant is chosen from anionic surfactants such as sulphates, for example sodium dodecyl sulphate (SDS). Preferably, the nonionic surfactant may be any copolymer having at least two parts of different polarities conferring properties of amphiphilic macromolecules. These copolymers can be part of the non-exhaustive list of the following families of copolymers: fluorinated copolymers (- [CH ₂ -CH ₂ -CH ₂ -CH ₂ -O-CO-R 1-with R 1 = C ₄ F ₉ , C ₈ F ₁₇ , etc.), biological copolymers such as polyamino acids (poly-lysine, alginates, etc.), dendrimers, block copolymers consisting of poly (alkylene oxide) chains and any other known amphiphilic copolymers of the skilled person ( S. Förster, M. Antionnetti, Adv.Mater, 1998, 10, 195-217 ; S. Förster, T.Plantenberg, Angew. Chem. Int. Ed, 2002, 41, 688-714 ; H. Cölfen, Macromol Rapid Common, 2001, 22, 219-252 ).

In the context of the present invention, a block copolymer consisting of poly (alkylene oxide) chains is preferably used. Said block copolymer is preferably a block copolymer having two, three or four blocks, each block consisting of a poly (alkylene oxide) chain. For a two-block copolymer, one of the blocks consists of a poly (alkylene oxide) chain of hydrophilic nature and the other block consists of a poly (alkylene oxide) chain of a nature hydrophobic. For a three-block copolymer, two of the blocks consist of a chain of poly (alkylene oxide) of hydrophilic nature while the other block, located between the two blocks with the hydrophilic parts, consists of a chain of poly (alkylene oxide) hydrophobic nature. Preferably, in the case of a three-block copolymer, the hydrophilic poly (alkylene oxide) chains are poly (ethylene oxide) chains denoted (PEO) _x and (PEO) _z and the Poly (alkylene oxide) chains of hydrophobic nature are chains of poly (propylene oxide) denoted (PPO) y, poly (butylene oxide) chains, or mixed chains, each chain of which is a mixture of several alkylene oxide monomers. Very preferably, in the case of a three-block copolymer, a compound is used. consisting of two chains of poly (ethylene oxide) and a poly (propylene oxide) chain and more particularly, it is the compound of formula (PEO) _x - (PPO) _y - (PEO) _z where x is between 5 and 300 and y is between 33 and 300 and z is between 5 and 300. Preferably, the values of x and z are the same. A compound is advantageously used in which x = 20, y = 70 and z = 20 (P123) and a compound in which x = 106, y = 70 and z = 106 (F127). Commercial nonionic surfactants known as Pluronic (BASF), Tetronic (BASF), Triton (Sigma), Tergitol (Union Carbide), Brij (Aldrich) are useful as nonionic surfactants in step b ) of the preparation process of the invention. For a four-block copolymer, two of the blocks consist of a poly (alkylene oxide) chain of hydrophilic nature and the other two blocks consist of a chain of poly (alkylene oxide) hydrophobic nature.

The solution obtained at the end of step b) of the process for preparing the material according to the invention in which at least said surfactant and at least said clear solution obtained according to step a) are mixed can be acidic, neutral or basic. Preferably, said solution is basic and preferably has a pH greater than 9, this pH value being generally imposed by the pH of the clear solution containing the precursor elements of zeolitic entities obtained according to step a) of the preparation process of the material according to the invention. The solution obtained at the end of step b) may be aqueous or may be a water-organic solvent mixture, the organic solvent preferably being a polar solvent, in particular an alcohol, preferably ethanol.

The amount of surfactant introduced into the mixture according to step b) of the preparation process according to the invention is defined with respect to the amount of inorganic material introduced into said mixture during the addition of the clear solution containing the precursor elements. of zeolitic entities obtained according to step a) of the process according to the invention. The amount of inorganic material corresponds to the amount of silicic precursor material and that of the element X precursor when present. The inorganic molar ratio. The _surfactant is such that the organic-inorganic binary system formed during the atomization step c) of the process for preparing the material according to the invention undergoes a phase separation characterized by the appearance of an interconnected biphasic network of which the mechanism of formation is a spinodal decomposition. The composition domain for which a phase separation occurs by a spinodal decomposition mechanism is delimited by limits for which the free enthalpy G of the binary system is minimized (∂G / ∂x = 0, x being the molar fraction of the organic phase, 1-x that of the inorganic phase) and for each composition belonging to this domain, the second derivative of the enthalpy ∂ ² G / ∂ ² x is greater than 0. The principle of phase separation via a mechanism of spinodal decomposition has been widely described by Nakanishi for obtaining silica gels in the presence of polymers ( K. Nakanishi, Journal of Porous Materials, 1997, 4, 67 ). The particular interconnection of the organic-inorganic biphasic network resulting from this phase separation phenomenon by spinodal decomposition is at the origin of the particular mesoporous and macroporous texture presented by the material according to the invention. According to step b) of the process according to the invention, the initial concentration of surfactant, introduced into the mixture, defined by c ₀ is such that c ₀ is less than or equal to c _mc , the parameter c _mc representing the micellar concentration criticism well known to those skilled in the art, that is to say the limit concentration beyond which occurs the phenomenon of self-arrangement of surfactant molecules in the solution. Before atomization, the concentration of surfactant molecules in the solution defined by step b) of the process for preparing the material according to the invention therefore does not lead to the formation of particular micellar phases. In a preferred implementation of the process according to the invention, the concentration c ₀ is less than the c _mc , the ratio n _Inorganic / n _Tensloactif is such that the composition of the binary system verifies the composition conditions for which a separation mechanism of phase occurs by spinodal decomposition and said solution referred to in step b) of the preparation process according to the invention is a basic water-alcohol mixture.

The step of atomizing the mixture according to step c) of the preparation process according to the invention produces spherical droplets. The size distribution of these droplets is lognormal. The aerosol generator used here is a commercial model 9306A device provided by TSI having a 6-jet atomizer. The atomization of the solution is done in a chamber into which a carrier gas, a mixture O ₂ / N ₂ (dry air), is sent under a pressure P equal to 1.5 bar.

According to step d) of the preparation process according to the invention, said droplets are dried. This drying is carried out by transporting said droplets via the carrier gas, the O ₂ / N ₂ mixture, in PVC tubes, which leads to the gradual evaporation of the solution, for example from the basic aqueous-organic solution obtained. during step b) of the process for preparing the material according to the invention, and thus obtaining spherical elementary particles. This drying is perfect by a passage of said particles in an oven whose temperature can be adjusted, the usual range of temperature ranging from 50 to 600 ° C and preferably from 80 to 400 ° C, the residence time of these particles in the oven being of the order of the second. The particles are then harvested in a filter. A pump placed at the end of the circuit promotes the routing of species in the aerosol experimental device. Drying the droplets according to step d) of the process according to the invention is advantageously followed by a passage in the oven at a temperature between 50 and 150 ° C.

According to step e) of the process according to the invention, the dried particles obtained according to step d) of the process according to the invention are autoclaved in the presence of a solvent. This step consists in placing said particles in a closed chamber in the presence of a solvent at a given temperature so as to work with autogenous pressure inherent to the operating conditions chosen. The solvent used is a protic polar solvent. Preferably the solvent used is water. The volume of solvent introduced is defined relative to the volume of the autoclave selected. Thus the volume of solvent introduced is in a range of 0.01 to 20% relative to the volume of the autoclave chosen, preferably in a range of 0.05 to 5% and preferably in a range of 0, 05 to 1%. The autoclaving temperature is between 50 and 200 ° C, preferably between 60 and 170 ° C and more preferably between 60 and 120 ° C so as to allow the growth of zeolite entities in the walls of the matrix of each of the particles of the material according to the invention without generating large size zeolite crystals which would disorganize the mesoporosity and macroporosity created within each particle of the material according to the invention. Autoclaving is maintained over a period of 1 to 96 hours and preferably over a period of 20 to 50 hours.

According to step f) of the preparation process according to the invention, the drying of the particles after autoclaving is advantageously carried out by placing in an oven at a temperature of between 50 and 150 ° C.

In the particular case where the element X, optionally used for the implementation of step a) of the process according to the invention, is the aluminum element and where the sodium element is present in the clear solution obtained in accordance with step a) of the process according to the invention via the use of sodium hydroxide and / or a sodic structuring agent ensuring the basicity of said clear solution, it is preferred to carry out an additional ion exchange step allowing the exchange of the Na ⁺ cation by the NH ₄ ⁺ cation between steps f) and g) of the process according to the invention. This exchange, which leads to the formation of protons H ⁺ after step g) of the process according to the invention in the preferred case where the removal of the structuring agent and the surfactant is carried out by calcination under air, is carried out according to operating protocols well known to those skilled in the art. One of the usual methods consists in suspending the dried solid particles from step f) of the process according to the invention in an aqueous solution of ammonium nitrate. The whole is then refluxed for 1 to 6 hours. The particles are then recovered by filtration (centrifugation at 9000 rpm), washed and then dried by passing in an oven at a temperature between 50 and 150 ° C. This ion exchange / washing / drying cycle can be repeated several times and preferably two more times. This exchange cycle can also be performed after steps f) and g) of the process according to the invention. Under these conditions, step g) is then reproduced after the last exchange cycle so as to generate H ⁺ protons as explained above.

According to step g) of the preparation process according to the invention, the elimination of the structuring agent and the surfactant, in order to obtain the material according to the invention with hierarchical porosity, is advantageously carried out by processes of chemical extraction or by heat treatment and preferably by calcination in air in a temperature range of 300 to 1000 ° C and more precisely in a range of 400 to 600 ° C for a period of 1 to 24 hours and preferably during a duration of 2 to 12 hours.

In the case where the solution referred to in step b) of the preparation process according to the invention is a water-organic solvent mixture, preferably a basic one, it is essential during step b) of the preparation process according to the invention. It is an object of the present invention that the surfactant concentration is less than the critical micellar concentration and that the n- _inorganic ratio of the _surfactant is such that the variation of the free mixture enthalpy ΔG _m and the second derivative of the free enthalpy ∂ ² G / ∂ ² x are greater than 0 so that the evaporation of said aqueous-organic solution, preferably basic, during step c) of the preparation process according to the invention by the aerosol technique induces a separation phenomenon organic and inorganic phases by spinodal decomposition leading to the generation of the mesoporous and macroporous phases of the spherical particles of the material according to the invention. Said phase separation observed is consecutive to a progressive concentration, within each droplet, of the silicic precursor, optionally of the precursor of the element X, preferably of the aluminum precursor and of the surfactant resulting from evaporation of the aqueous-organic solution preferentially basic, until a concentration of reagents sufficient to cause said phenomenon.

The hierarchically porous material of the present invention can be obtained in the form of powder, beads, pellets, granules, or extrusions, the shaping operations being carried out by conventional techniques known to those skilled in the art. . Preferably, the material having a hierarchical porosity according to the invention is obtained in the form of a powder, which consists of elementary spherical particles having a maximum diameter of 200 microns, which facilitates the possible diffusion of the reagents in the case of the use of the material according to the invention in a potential industrial application.

The material of the invention with hierarchical porosity is characterized by several analysis techniques and in particular by large-angle X-ray diffraction (XRD), by nitrogen volumetry (BET), by mercury porosimetry, by electron microscopy. transmission (TEM), scanning electron microscopy (SEM) and X-ray fluorescence (FX).

The technique of X-ray diffraction at large angles (values of the angle 2θ between 5 and 70 °) makes it possible to characterize a crystallized solid defined by the repetition of a unitary unit or unit cell at the molecular scale. In the following discussion, the X-ray analysis is performed on powder with a diffractometer operating in reflection and equipped with a rear monochromator using copper radiation (wavelength 1.5406 A). The peaks usually observed on the diffractograms corresponding to a given value of the angle 2θ are associated with the inter-reticular distances d _(hkl) characteristic of the structural symmetry (s) of the material, ((hkl) being the Miller indices of the reciprocal lattice) by the Bragg relation: 2 d _(hkl) * sin (θ) = n * λ. This indexing then allows the determination of the mesh parameters (abc) of the direct network. The wide-angle XRD analysis is therefore adapted to the structural characterization of the zeolite entities constituting the crystallized wall of the matrix of each of the elementary spherical particles constituting the material according to the invention. In particular, it provides access to the pore size of the zeolite entities. For example, the large-angle X-ray diffractogram of a mesoporous and macroporous porosity material, whose microporous walls of the matrix of each of the spherical particles consist of zeolite entities ZSM-5 (MFI), obtained according to FIG. process according to the invention using TEOS as silicic precursor; Al (O ^s C ₄ H ₉ ) ₃ as an aluminum precursor, TPAOH as a structuring agent and the particular block copolymer called poly (ethylene oxide) ₁₀₆ -poly (propylene oxide) ₇₀ -poly (ethylene oxide) ₁₀₆ (PEO ₁₀₆ -PPO ₇₀ -PEO ₁₀₆ or F127) as surfactant exhibits the diffractogram associated with the Pnma symmetry group (No. 62) of zeolite ZSM-5 at large angles. The value of the angle obtained on the diffractogram RX makes it possible to go back to the correlation distance d according to the Bragg law: 2 d ^* sin (θ) = n ^* λ. The values of the parameters of mesh a, b, c (a = 20.1 Å, b = 19.7 Å and c = 13.1 Å) obtained for the characterization of the zeolite entities are coherent with the values obtained for a zeolite ZSM -5 (MFI structural type) well known to those skilled in the art ( ' Collection of simulated XRD powder patterns for zeolites ", 4th revised edition, 2001, MMJ Treacy, JB Higgins ).

Nitrogen volumetry, which corresponds to the physical adsorption of nitrogen molecules in the porosity of the material via a progressive increase in pressure at constant temperature, provides information on textural characteristics (pore diameter, porosity type, specific surface area). of the material obtained according to the process of the invention. In particular, it provides access to the total value of the microporous and mesoporous volume of the material. The shape of the nitrogen adsorption isotherm and the hysteresis loop can provide information on the presence of the microporosity linked to the zeolitic entities constituting the crystallized walls of the matrix of each of the spherical particles of the material according to the invention. and the nature of mesoporosity. The quantitative analysis of the microporosity of the material according to the invention is carried out using methods "t" (method Lippens-De Boer, 1965) or "α _s " (method proposed by Sing) that correspond to transformations of the isothermal adsorption starting as described in the book " Adsorption by powders and porous solids. Principles, methodology and applications "written by F. Rouquerol, J. Rouquerol and K. Sing, Academic Press, 1999 . These methods make it possible to access in particular the value of the microporous volume characteristic of the microporosity of the material according to the invention as well as the specific surface of the sample. The reference solid used is LiChrospher Si-1000 silica ( M. Jaroniec, M. Kruck, JP Olivier, Langmuir, 1999, 15, 5410 ). For example, the nitrogen adsorption isotherm of a mesoporous and macroporous porosity material, whose microporous walls of the matrix of each of the spherical particles consist of zeolite entities ZSM-5 (MFI), obtained according to the process for the preparation of the material according to the invention using TEOS as silicic precursor, Al (O ^s C ₄ H ₉ ) ₃ as an aluminum precursor, TPAOH as structuring agent and the particular block copolymer called poly (ethylene oxide) ₁₀₆ -poly (propylene oxide) ₇₀ -poly (ethylene oxide) ₁₀₆ (PEO ₁₀₆ -PPO ₇₀ -PEO ₁₀₆ or F127) as surfactant exhibits a high adsorption jump in the low P / P0 domain ( where P0 is the saturated vapor pressure at temperature T) followed by a plateau of very low slope over a large pressure range, characteristics of a microporous material as well as a type IV isotherm and a hysteresis loop of type H1 in the field of val High levels of representative P / P0 of mesopores ranging in size from 1.5 to 50 nm. Similarly, the curve V _ads (ml / g) = f (α _s ) obtained via the α _s method mentioned above is characteristic of the presence of microporosity within the material and leads to a value of the microporous volume included in a range from 0.03 to 0.4 ml / g. Determination of total microporous and mesoporous volume and volume microporous as described above leads to a value of the mesoporous volume of the material according to the invention in a range of 0.01 to 1 ml / g

The mercury porosimetry analysis corresponds to the intrusion of a volume of mercury characteristic of the existence of mesopores and macropores in the material according to the invention according to the ASTM D4284-83 standard at a maximum pressure of 4000 bar, using a surface tension of 484 dyne / cm, and a contact angle of 140 ° (value chosen according to the recommendations of the book " Technique of the engineer, treated analysis and characterization ", page 1050, written by J. Charpin and B. Rasneur ) and the pores are assumed to be cylindrical in shape. This technique is perfectly suited to the analysis of mesoporous and macroporous samples in addition to the nitrogen volumetric analysis technique described above. In particular, this technique makes it possible to access the value of the mesoporous mercury volume (V _Hgmeso in ml / g) defined as being the mercury volume adsorbed by all the pores having a diameter included in the range of mesopores, namely between 3.6 nm and 50 nm (value of the upper limit as defined by the IUPAC standard). Similarly, the macroporous mercury volume (V _Hgmacro in ml / g) is defined as the mercury volume adsorbed by all the pores having a diameter greater than 50 nm. For example, the mercury porosimetry analysis of a mesoporous and macroporous porosity material, the microporous walls of the matrix of each of the spherical particles consist of zeolite entities ZSM-5 (MFI), obtained according to the method. of the invention using TEOS as a silicic precursor, Al (O ^s C ₄ H ₉ ) ₃ as an aluminum precursor, TPAOH as a structuring agent and the particular block copolymer called poly (ethylene oxide) ₁₀₆ -poly (oxide of propylene) _70- poly (ethylene oxide) ₁₀₆ (PEO ₁₆₀ -PPO ₇₀ -PEO ₁₀₆ or F127) as surfactant leads to a mesoporous mercury volume ranging from 0.01 to 1 ml / g and a volume of macroporous mercury in a range of 0.05 to 1 ml / g.

Transmission electron microscopy (TEM) analysis is a technique also widely used to characterize the mesoporosity and macroporosity of the material according to the invention. This allows the formation of an image of the studied solid, the observed contrasts being characteristic of the structural organization, the texture, the morphology or the chemical composition of the particles observed, the resolution of the technique reaching the maximum 0.2 nm. In the following description, the TEM photos will be made from microtome sections of the sample in order to visualize a section of an elementary spherical particle of the material according to the invention. For example, the MET images obtained for a mesoporous and macroporous porosity material whose walls microporous particles consist of zeolite entities ZSM-5 (MFI) obtained according to the preparation method according to the invention using TEOS as silicic precursor, Al (O ^s C ₄ H ₉ ) ₃ as an aluminum precursor, TPAOH as structuring agent and the particular block copolymer designated poly (ethylene oxide) ₁₀₆ - _P oly (propylene oxide) _70- poly (ethylene oxide) ₁₀₆ (PEO ₁₀₆ -PPO ₇₀ -PEO ₁₀₆ or F127) as surfactant have within of the same spherical particle, a mesoporosity and a macroporosity characteristic of an organic-inorganic phase separation by a spinodal decomposition mechanism subsequent to the atomization stage c) of the process for preparing the material according to the invention, the size of which domains is respectively in a range of 15 to 50 nm and in a range of 100 to 500 nm. The analysis of the image also makes it possible to visualize the presence of the zeolite entities constituting the walls of the material according to the invention.

The morphology and size distribution of the elementary particles were established by scanning electron microscopy (SEM) photo analysis.

The present invention also relates to the use of the hierarchically porous material according to the invention as an adsorbent for the control of pollution or as a molecular sieve for separation. The present invention therefore also relates to an adsorbent comprising the hierarchically porous material according to the invention. It is also advantageously used as an acid solid to catalyze reactions, for example those involved in the fields of refining and petrochemistry.

When the hierarchically porous material according to the invention is used as a catalyst, this material may be associated with an inorganic matrix which may be inert or catalytically active and with a metallic phase. The inorganic matrix may be present simply as a binder to hold together the particles of said material in the various known forms of the catalysts (extrudates, pellets, beads, powders) or may be added as a diluent to impose the degree of conversion in a process which otherwise would progress at too fast a rate, leading to clogging of the catalyst as a result of a significant formation of coke. Typical inorganic matrices are, in particular, support materials for catalysts, such as the various forms of silica, alumina, silica-alumina, magnesia, zirconia, titanium oxides, boron oxides, aluminum phosphates, titanium, zirconium, clays such as kaolin, bentonite, montmorillonite, sepiolite, attapulgite, fuller's earth, synthetic porous materials such as SiO ₂ -Al ₂ O ₃ , SiO ₂ -ZrO ₂ , SiO ₂ -ThO ₂ , SiO ₂ -BeO SiO ₂ -TiO ₂ or any combination of these compounds. The inorganic matrix may be a mixture of different compounds, in particular an inert phase and an active phase. Said material of the present invention may also be associated with at least one zeolite and play the role of main active phase or additive. The metal phase can be introduced integrally on said material of the invention. It may also be introduced integrally onto the inorganic matrix or onto the inorganic matrix-ionized porosity hierarchical material or impregnation with cations or oxides chosen from the following elements: Cu, Ag, Ga, Mg, Ca , Sr, Zn, Cd, B, Al, Sn, Pb, V, P, Sb, Cr, Mo, W, Mn, Re, Fe, Co, Ni, Pt, Pd, Ru, Rh, Os, Ir and all other element of the periodic table of elements.

The catalyst compositions comprising the material of the present invention are generally suitable for carrying out the main hydrocarbon conversion processes and organic compound synthesis reactions.

The catalyst compositions comprising the material of the invention advantageously find their application in isomerization, transalkylation and disproportionation, alkylation and dealkylation, hydration and dehydration, oligomerization and polymerization, cyclization reactions. , aromatization, cracking, reforming, hydrogenation and dehydrogenation, oxidation, halogenation, hydrocracking, hydroconversion, hydrotreatment, hydrodesulfurization and hydrodenitrogenation, catalytic removal nitrogen oxides, said reactions involving fillers comprising saturated and unsaturated aliphatic hydrocarbons, aromatic hydrocarbons, oxygenated organic compounds and organic compounds containing nitrogen and / or sulfur as well as organic compounds containing other functional groups.

The invention is illustrated by means of the following examples.

EXAMPLES

In the examples which follow, the aerosol technique used is that described above in the description of the invention.

For each of the examples below, the ratio V _inorganic / V _organic of the mixture resulting from step b) is calculated. This ratio is defined as follows: _inorganic V / _organic V = (m _inorg * ρ _org ) / (m _org * ρ _inorg ) with m _inorg the final mass of the inorganic fraction in oxide form (s) condensed (s), namely SiO ₂ and AlO ₂ , in the solid elementary particle, m _org the total mass of the nonvolatile organic fraction found in the solid elementary particle, namely the surfactant and the structuring agent, ρ _org and ρ _inorg the densities respectively associated with the nonvolatile and inorganic organic fractions. In the following examples, it is considered that ρ _org = 1 and ρ _inorg = 2. Also the ratio V _inorganic / V _organic is calculated as being equal to V _inorganic / N _organic = (M _SiO2 + m _AlO2 ) [2 * ( m structuring _agent + M _surfactant )]. Ethanol, sodium hydroxide and water are not taken into account in the calculation of said _inorganic V / _organic N ratio.

Example 1 (Invention): Preparation of a material having a Si / Al = 50 molar ratio with mesoporous and macroporous porosity, the microporous walls of which consist of crystalline zeolite entities ZSM-5 (MFI)

10.05 g of a solution of tetrapropylammonium hydroxide (TPAOH 20% by weight in an aqueous solution) are added to 4.3 g of demineralized water and 9.2 mg of sodium hydroxide NaOH. The whole is left stirring for 10 minutes. 0.14 g of aluminum sec-butoxide (Al (O ^s C ₄ H ₉ ) ₃ are then introduced, the hydrolysis of the aluminum precursor is carried out for 1 hour, 6 g of tetraethylorthosilicate (TEOS) are then added. all is stirred for 18 hours at room temperature so as to obtain a clear solution, 18 ml of this solution are then added to a solution containing 35.2 g of ethanol, 11.3 g of water and 2 g of water. surfactant F127 (pH of the mixture = 10.5) The _inorganic V / _organic N ratio of the mixture is equal to 0.20 and is calculated as described above, the whole is left stirring for 10 minutes. sent to the atomization chamber of the aerosol generator as described in the description above and the solution is sprayed in the form of fine droplets under the action of the carrier gas (dry air) introduced under pressure (P = 1.5 bar) The droplets are dried according to the protocol described in According to the invention above, they are conveyed via an O ₂ / N ₂ mixture into PVC tubes. They are then introduced into an oven set at a temperature of 250 ° C to complete their drying for a period of about one second. The harvested powder is then dried for 12 hours in an oven at 95 ° C. 10 mg of powder are then placed in a 100 ml autoclave (closed chamber capable of withstanding temperatures of the order of 200 ° C. and pressures of the order of 5 bars) in the presence of 100 μl of demineralised water . The autoclave is provided with a system of "basket" or "cell" allowing the powder not to be in direct contact with the water introduced while bathing in the water vapor. The autoclave is then heated to a temperature of 95 ° C for 48 hours. hours. The recovered powder is then dried in an oven at 95 ° C. for 12 hours. The powder is then calcined under air for 5 hours at T = 550 ° C. The solid is characterized by XRD, nitrogen volumetry, mercury porosimetry, TEM, SEM, FX. The TEM analysis shows that the spherical constitutive particles of the material have a core macroporosity characterized by domains 300 to 500 nm long and 100 to 200 nm wide and a mesoporosity at the periphery of the particles characterized by domains of 20 to 50 nm, the set being characteristic of an organic-inorganic phase separation obtained by a spinodal decomposition mechanism present before the calcination step. The presence of zeolite entities in the walls of the material is also clearly visible during the study by electron diffraction of the michronotropic sections with a thickness of the order of 70 nm on localized areas of the order of 100 nm. Nitrogen volumetric analysis combined with analysis by the α _s method leads to a microporous volume V _{micro value} of 0.26 ml / g (N ₂ ), a mesoporous V _meso volume value of 0, 6 ml / g (N ₂ ) and a specific surface area of the final material of S = 690 m ² / g. The macroporous mercury volume defined by mercury porosimetry is 0.5 ml / g (the value of the mercury mercury volume also obtained by mercury porosimetry is in perfect agreement with the value obtained by nitrogen volumetry). The wide-angle XRD analysis leads to obtaining the diffractogram characteristic of the zeolite ZSM-5 (size of the micopores, measured by XRD, of the order of 0.55 nm). The molar Si / Al ratio obtained by FX is 50. An SEM image of the spherical elementary particles thus obtained indicates that these particles have a size characterized by a diameter ranging from 50 to 700 nm, the size distribution of these particles being centered around 300 nm.

Example 2 (Invention): Preparation of a mesoporous and macroporous porosity material whose microporous walls consist of crystallized entities of zeolite silicalite (MFI).

10.05 g of a solution of tetrapropylammonium hydroxide (TPAOH 20% by weight in an aqueous solution) are added to 4.3 g of demineralized water and 9.2 mg of sodium hydroxide NaOH. The whole is left stirring for 10 minutes. 6 g of tetraethylorthosilicate (TEOS) are then added. The whole is stirred for 18 hours at room temperature so as to obtain a clear solution. 18 ml of this solution are then added to a solution containing 35.2 g of ethanol, 11.3 g of water and 2 g of surfactant F127 (pH of the mixture = 10.5). The ratio V _inorganic / V _organic mixture is 0.20 and is calculated as described above. The whole is left stirring for 10 minutes. The assembly is sent into the atomization chamber of the aerosol generator as described in the description above and the solution is sprayed in the form of fine droplets under the action of the carrier gas (dry air ) introduced under pressure (P = 1.5 bar). The droplets are dried according to the protocol described in the disclosure of the invention above: they are conveyed via an O ₂ / N ₂ mixture in PVC tubes. They are then introduced into an oven set at a drying temperature set at 250 ° C. The harvested powder is then dried for 12 hours in an oven at 95 ° C. 10 mg of powder are then placed in a 100 ml autoclave (closed chamber capable of withstanding temperatures of the order of 200 ° C. and pressures of the order of 5 bars) in the presence of 100 μl of demineralised water . The autoclave is provided with a system of "basket" or "cell" allowing the powder not to be in direct contact with the water introduced while bathing in the water vapor. The autoclave is then heated to a temperature of 95 ° C for 36 hours. The recovered powder is then dried in an oven at 95 ° C. for 12 hours. The powder is then calcined under air for 5 hours at 550 ° C. The solid is characterized by XRD, nitrogen volumetry, mercury porosimetry, TEM, SEM. The TEM analysis shows that the spherical constitutive particles of the material have a core macroporosity characterized by domains 300 to 500 nm long and 100 to 200 nm wide and a mesoporosity at the periphery of the particles characterized by domains of 20 to 50 nm, the set being characteristic of an organic-inorganic phase separation obtained by a spinodal decomposition mechanism present before the calcination step. The presence of zeolite entities in the walls of the material is also clearly visible during the study by electron diffraction of the michronotropic sections with a thickness of the order of 70 nm on localized areas of the order of 100 nm. Nitrogen volumetric analysis combined with analysis by the α _s method leads to a microporous volume V _{micro value} of 0.3 ml / g (N ₂ ), a mesoporous V _meso volume value of 0, 6 ml / g (N ₂ ) and a specific surface area of the final material of S = 680 m ² / g. The macroporous mercury volume defined by mercury porosimetry is 0.5 ml / g (the value of the mesoporous mercury volume also obtained is in perfect agreement with the value obtained by volumetric nitrogen). The wide-angle XRD analysis leads to obtaining the diffractogram characteristic of the zeolite silicalite (size of the micropores, measured by XRD, of the order of 0.55 nm). An SEM image of the spherical elementary particles thus obtained indicates that these particles have a size characterized by a diameter ranging from 50 to 700 nm, the size distribution of these particles being centered around 300 nm.

Example 3 (Invention): Preparation of a mesoporous and macroporous porosity material whose microporous walls consist of crystallized entities of zeolite beta (BEA) and having a molar ratio Si / Al = 50.

11.70 g of a solution of tetraethylammonium hydroxide hydroxide (TEAOH 20% by weight in an aqueous solution) are added to 7.8 g of demineralized water and 0.03 g of sodium hydroxide NaOH. The whole is left stirring for 10 minutes. 0.14 g of aluminum sec-butoxide (Al (O ^s C ₄ H ₉ ) ₃ ) are then introduced. The whole is left stirring for 10 minutes. The hydrolysis of the aluminum precursor is carried out for 1 hour. 6 g of tetraethylorthosilicate (TEOS) are then added. The whole is stirred for 18 hours at room temperature so as to obtain a clear solution. 18 ml of this solution are then added to a solution containing 35.2 g of ethanol, 11.3 g of water and 2 g of surfactant F127 (pH of the mixture = 10). The _inorganic / _organic V ratio of the mixture is 0.17 and is calculated as described above. The whole is left stirring for 10 minutes. The assembly is sent into the atomization chamber of the aerosol generator as described in the description above and the solution is sprayed in the form of fine droplets under the action of the carrier gas (dry air ) introduced under pressure (P = 1.5 bar). The droplets are dried according to the protocol described in the disclosure of the invention above: they are conveyed via an O ₂ / N ₂ mixture in PVC tubes. They are then introduced into an oven set at a drying temperature set at 250 ° C. The harvested powder is then dried for 12 hours in an oven at 95 ° C. 10 mg of powder are then placed in a 100 ml autoclave (closed chamber capable of withstanding temperatures of the order of 200 ° C. and pressures of the order of 5 bars) in the presence of 150 μl of demineralised water . The autoclave is provided with a system of "basket" or "cell" allowing the powder not to be in direct contact with the water introduced while bathing in the water vapor. The autoclave is then heated to a temperature of 95 ° C for 48 hours. The recovered powder is then dried in an oven at 95 ° C. for 12 hours. The powder is then calcined under air for 5 hours at 550 ° C. The solid is characterized by XRD, nitrogen volumetry, mercury porosimetry, TEM, SEM, FX. The TEM analysis shows that the spherical constitutive particles of the material have a core macroporosity characterized by domains 300 to 500 nm long and 100 to 200 nm wide and a mesoporosity at the periphery of the particles characterized by domains of 20 to 50 nm, the whole being characteristic of a phase separation organic - inorganic obtained by a spinodal decomposition mechanism present before the calcination step. The presence of zeolite entities in the walls of the material is also clearly visible during the study by electron diffraction of the michronotropic sections with a thickness of the order of 70 nm on localized areas of the order of 100 nm. Nitrogen volumetric analysis combined with analysis by the α _s method leads to a microporous volume V _{micro value} of 0.35 ml / g (N ₂ ), a mesoporous V _meso volume value of 0, 6 ml / g (N ₂ ) and a specific surface area of the final material of S = 700 m ² / g. The macroporous mercury volume defined by mercury porosimetry is 0.3 ml / g (the value of the mesoporous mercury volume also obtained is in perfect agreement with the value obtained by nitrogen volumetry). The wide-angle X-ray analysis leads to the characteristic diffractogram of zeolite beta (size of the micopores, measured by XRD, of the order of 0.66 nm). The molar Si / Al ratio obtained by FX is 50. An SEM image of the spherical elementary particles thus obtained indicates that these particles have a size characterized by a diameter ranging from 50 to 700 nm, the size distribution of these particles being centered around 300 nm.

Exempt 4 (Invention): Preparation of a material with mesoporous and macroporous porosity whose microporous walls consist of crystallized entities of zeolite Y (FAU) and having a molar ratio Si / Al = 8.

0.41 g of sodium aluminate (NaAlO ₂ ) are added to a solution containing 0.17 g of sodium hydroxide and 7.6 g of demineralized water. The solution is stirred until the aluminum precursor is dissolved. 10 g of sodium silicate (27% by weight of SiO ₂ and 14% of NaOH) are then added with vigorous stirring. The whole is stirred for 18 hours at room temperature so as to obtain a clear solution. 15 ml of this solution are then added to a solution containing 35.2 g of ethanol, 11.6 g of water and 6.3 g of surfactant F127 (pH of the mixture = 9.8). The _inorganic / _organic V ratio of the mixture is 0.24 and is calculated as described above. The whole is left stirring for 10 minutes. The assembly is sent into the atomization chamber of the aerosol generator as described in the description above and the solution is sprayed in the form of fine droplets under the action of the carrier gas (dry air ) introduced under pressure (P = 1.5 bar). The droplets are dried according to the protocol described in the disclosure of the invention above: they are conveyed via an O ₂ / N ₂ mixture in PVC tubes. They are then introduced into an oven set at a temperature drying time set at 250 ° C. The harvested powder is then dried for 12 hours in an oven at 95 ° C. 10 mg of powder are then placed in a 100 ml autoclave (closed chamber capable of withstanding temperatures of the order of 200 ° C. and pressures of the order of 5 bars) in the presence of 150 μl of demineralised water . The autoclave is provided with a system of "basket" or "cell" allowing the powder not to be in direct contact with the water introduced while bathing in the water vapor. The autoclave is then heated to a temperature of 95 ° C for 48 hours. The recovered powder is then dried in an oven at 95 ° C. for 12 hours. The powder is then calcined under air for 5 hours at 550 ° C. The solid is characterized by XRD and at large angles, by nitrogen volumetry, by mercury porosimetry, by TEM, by SEM and by ICP, by FX. The TEM analysis shows that the spherical constitutive particles of the material have a core macroporosity characterized by domains 300 to 500 nm long and 100 to 200 nm wide and a mesoporosity at the periphery of the particles characterized by domains of 20 to 50 nm, the set being characteristic of an organic-inorganic phase separation obtained by a spinodal decomposition mechanism present before the calcination step. The presence of zeolite entities in the walls of the material is also clearly visible during the study by electron diffraction of the michronotropic sections with a thickness of the order of 70 nm on localized areas of the order of 100 nm. The analysis by nitrogen volumetric analysis combined with the α _s method leads to a value of the micropore volume V _micro of 0.33 ml / g (N _2), a value of the mesopore volume V _meso 0, 8 ml / g (N ₂ ) and a specific surface area of the final material of S = 720 m ² / g. The macroporous mercury volume defined by mercury porosimetry is 0.5 ml / g (the value of the mesoporous mercury volume also obtained is in perfect agreement with the value obtained by volumetric nitrogen). The wide-angle XRD analysis leads to obtaining the diffractogram characteristic of zeolite Y (size of the micopores, measured by XRD, of the order of 0.8 nm). The Si / Al molar ratio obtained by FX is 8. An SEM image of the spherical elementary particles thus obtained indicates that these particles have a size characterized by a diameter ranging from 50 to 700 nm, the size distribution of these particles being centered around 300 nm.

Claims (19)

1. A hierarchical porosity material consisting of at least two elementary spherical particles having a maximum diameter of 200 microns, at least one of said spherical particles comprises at least one matrix based on silicon oxide and exhibiting crystallized walls, said material having a macropore volume measured by mercury porosimetry ranging between 0.05 and 1 ml/g, a mesopore volume measured by nitrogen volumetric analysis ranging between 0.01 and 1 ml/g and a micropore volume measured by nitrogen volumetric analysis ranging between 0.03 and 0.4 ml/g.
2. A material as claimed in claim 1, such that the macropore volume measured by mercury porosimetry ranges between 0.1 and 0.3 ml/g.
3. A material as claimed in claim 1 or 2, such that the mesopore volume measured by nitrogen volumetric analysis ranges between 0.1 and 0.6 ml/g.
4. A material as claimed in any one of claims 1 to 3, such that macroporosity is present in domains ranging between 50 and 1000 nm.
5. A material as claimed in any one of claims 1 to 4, such that mesoporosity is present in domains ranging between 2 and 50 nm.
6. A material as claimed in any one of claims 1 to 5, such that it exhibits mesoporosity-free elementary spherical particles.
7. A material as claimed in any one of claims 1 to 6, such that said matrix has crystallized walls consisting of zeolitic entities.
8. A material as claimed in claim 7, such that said zeolitic entities comprise at least one zeolite selected from among the zeolites of MFI, BEA, FAU and LTA structural type.
9. A material as claimed in any one of claims 1 to 8, such that said matrix based on silicon oxide is entirely silicic.
10. A material as claimed in any one of claims 1 to 8, such that said matrix based on silicon oxide comprises at least one element X selected from among aluminium, iron, boron, indium and gallium.
11. A material as claimed in claim 10, such that element X is aluminium.
12. A material as claimed in any one of claims 1 to 11, such that said elementary spherical particles have a diameter ranging between 50 nm and 10 microns.
13. A material as claimed in any one of claims 1 to 12, such that it has a specific surface area ranging between 100 and 1100 m²/g.
14. A method of preparing a material as claimed in any one of claims 1 to 13, comprising: a) preparing a clear solution containing the zeolitic entity precursor elements, i.e. at least one structuring agent, at least one silicic precursor and possibly at least one precursor of at least one element X selected from among aluminium, iron, boron, indium and gallium ; b) mixing into a solution at least one surfactant and at least said clear solution obtained in stage a), the surfactant initial concentration being lower than the critical micellar concentration and the variation of the free enthalpy of mixing ΔG_m as well as the second derivative of the free enthalpy ∂²G/∂²x being greater than 0; c) aerosol atomizing said solution obtained in stage b) so as to lead to the formation of spherical droplets ; d) drying said droplets ; e) autoclaving the particles obtained in stage d) ; f) drying said particles obtained in stage e) ; and g) eliminating said structuring agent and said surfactant so as to obtain a hierarchical porosity crystallized material in the microporosity, mesoporosity and macroporosity range.
15. A method as claimed in claim 14, such that element X is aluminium.
16. A method as claimed in claim 14 or 15, such that said surfactant is a three-block copolymer, each block consisting of a poly(alkylene oxide) chain.
17. A method as claimed in claim 16, such that said three-block copolymer consists of two poly(ethylene oxide) chains and of one poly(propylene oxide) chain.
18. An adsorbent comprising the hierarchical porosity material as claimed in any one of claims 1 to 13 or prepared according to the method as claimed in any one of claims 14 to 17.
19. A catalyst comprising the hierarchical porosity material as claimed in any one of claims 1 to 13 or prepared according to the method as claimed in any one of claims 14 to 17.